Self-conforming screen

• US 7,013,979 B2
• Filed: 04/08/2005
• Issued: 03/21/2006
• Est. Priority Date: 08/23/2002
• Status: Expired due to Term

• Current Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Richard, Bennett M.
• Primary Examiner(s): DANG, HOANG C
• Application Number:
  US11/102,034
• Publication Number:
  US 20050173130A1
• Time in Patent Office: 347 Days
• Field of Search: 166/369, 166/382, 166/380, 166/206, 166/207, 166/227
• US Class Current: 166/369
• CPC Class Codes: E21B 43/086 Screens with preformed openings, e.g. slotted liners comprising porous materials E21B43/082
• CPC Class Codes: E21B 43/103 of expandable casings, screens, liners, or the like
• CPC Class Codes: E21B 43/108 Expandable screens or perforated liners

Abstract

A screen that conforms to the borehole shape after expansion is disclosed. The screen comprises a compliant outer layer that takes the borehole shape on expansion. The outer layer is formed having holes to permit production flow. The material that is selected preferably swells with prolonged contact to well fluids to further close off annular gaps after expansion. In an alternative embodiment, the screen is not expanded and the swelling of the material alone closes off annular gaps. The outer sleeve is placed over the screen and the screen is placed on a base pipe and initially expanded from within the base pipe to secure the components of the screen assembly for running downhole, while minimizing or eliminating any welding among the layers. A variety of expansion tools can be used to expand the screen or screens downhole.

Claims

1. A well completion method, comprising:

covering at least one opening on a tubular with an unrestrained conforming material said conforming material made of at least one segment;

running said tubular to a desired location in the wellbore;

allowing said unrestrained conforming material to enlarge into substantial contact with the wellbore;

taking flow through said at least one segment of said conforming material and then through said opening in said tubular after allowing said unrestrained conforming material to enlarge into contact with the wellbore.

2. The method of claim 1, comprising:

allowing said conforming material to enlarge to the shape of the surrounding wellbore.

3. The method of claim 1, comprising:

securing said conforming material to said tubular as a result of bonding.

4. The method of claim 2, comprising:

expanding said tubular and conforming material;

forcing said conforming material to flow along the wellbore by said expanding of said tubular.

5. The method of claim 1, comprising:

allowing said conforming material to swell.

6. The method of claim 5, comprising:

using well fluids to initiate said swelling.

7. The method of claim 1, comprising:

using a polymeric material as said conforming material.

8. A well completion method, comprising:

covering a tubular having at least one opening with an unrestrained conforming material;

running said tubular to a desired location in the wellbore;

allowing said unrestrained conforming material to enlarge;

securing said conforming material to said tubular by outward expansion of said tubular prior to said running said tubular into the wellbore.

9. A well completion method, comprising:

covering at least one opening on a tubular with a conforming material said conforming material made of at least one segment, said conforming material having a relaxed outer dimension in an unrestrained condition;

running said tubular to a desired location in the wellbore;

allowing said conforming material to enlarge beyond said relaxed outer dimension into substantial contact with the wellbore;

taking flow through said said at least one segment of said conforming material and then through said opening in said tubular after allowing said conforming material to enlarge into contact with the wellbore.

10. The method of claim 9, comprising:

using a polymeric material as said conforming material.

11. The method of claim 9, comprising:

allowing the conforming material to swell.

12. The method of claim 11, comprising:

using well fluids to initiate said swelling.

13. The method of claim 9, comprising:

expanding said tubular and conforming material;

forcing said conforming material to flow along the wellbore by said expanding of said tubular.

14. The method of claim 9, comprising:

allowing said conforming material to enlarge to the shape of the surrounding wellbore.

15. A well completion method, comprising:

covering a tubular having at least one opening with a conforming material, said conforming material having a relaxed outer dimension in an unrestrained condition;

running said tubular to a desired location in the wellbore;

allowing said conforming material to enlarge beyond said relaxed outer dimension;

securing said conforming material to said tubular by outward expansion of said tubular prior to said running said tubular into the wellbore.